GENERATOR USER`S MANUAL

Chapter I. Overview

This Manual is prepared in order for users to get a brief understanding on the
structure, performance, use and maintenance of the unit. Please refer to respective
instruction manuals enclosed with the unit for detailed instructions on the use and
care of all elements of diesel engine, generator and control panel.
Due to continuous optimization and improvement of production and
products, we reserve the right to improve products’ technical performances and
specifications without prior notice. Therefore, the user needs to be cautious that the
contents in this Manual may be slight different from the product. We sincerely
hope that users may reflect all problems found in their use and feedback their
precious suggestions for improvement in order for us to improve product quality
continuously and serve users better.

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Chapter II. Key Technical Performances & Use Conditions of the Unit

1. Key technical performances of the unit

(1) Power supply type: A.C.

(2) Rated rotating speed: 1,500/1,800rpm (3,000/3,600rpm optional)

(3) Rated frequency: 50/60Hz

(4) Rated voltage: line voltage 400V, phase voltage 230V

(5) Power factor: cosφ = 0.8 (lag)

(6) Phase number: 3-phase and 4-wire

(7) Cooling mode: open water circulation cooling or forced closed water circulation via fan and water box.

2. Ambient conditions for using the unit

(1) Altitude: ≤ 1,000m;

(2) Ambient temperature: ± 5oC ~ +40 oC;

(3) Relative humidity: ≤ 60% (20 oC);

(4) No conductive dust or corrosive gas which may destroy metal and insulation;

(5) No risk of explosion; No shaking or bumping;

3. Conditions for normal use of the unit

(1) Use clean diesel. Usually, domestically-produced light diesel above #0 Grade is used. The type of antifreeze diesel to be used depends
on the local temperature. Prior to use, diesel should go through a long settling or filtering treatment process to eliminate mechanical
impurities. The oil tank should be big enough, and is typically required to store the fuel necessary for 8-hour working. The lowest
position of the oil tank should not be 1m lower than the center of the fuel feed pump. The oil tank should not be near vent pipe or electric
equipment.

(2) The use of engine oil must satisfy relevant requirements: for the unit with the engine rotating speed of 1,500rpm, the high-speed diesel
engine oil must be used; for the unit with the engine rotating speed within 1,500rpm, the above-said engine is preferred; alternatively,
domestically-produced 15w-40CD or #HC-14 diesel engine oil may be used instead. Use clean engine oil. Prevent diesel or water from
getting in engine oil. Don’t use different grade engine oil at the same time.

(3) The pure antirust and antifreeze coolant should be used. Don’t use well water or underground water (hard water) because such water
contains a lot of mineral substances which are easy to fur up in the diesel engine to affect cooling effects. Never use sea water or salty
river water to avoid salt caking in the diesel engine under high temperature.

(4) When the diesel engine is working under the ambient temperature below 0oC, the coolant should be prevented from freezing up so as to
protect some parts from cracking. Therefore, when the diesel engine without antifreeze liquid finishes running, the coolants of each part
should be discharged; for the unit with the closed circulation cooling system, an appropriate antifreeze coolant may be selected for use
according to the local lowest temperature.

4. Outdoor use of the unit

(1) When the unit works outdoors, a rain shed should be erected to protect the unit from sunshine or rain.

(2) The output cables must be tidy, safe and reliable, but cannot be dragged randomly so as to ensure the safety of operators.

(3) The insulation of the output cables of the unit must be above 2MΩ (measured with 500VMΩ meter); otherwise, the unit is not allowed
to work.

5. Indoor use of the unit

(1) The distance from the water tank of the closed-cooling unit to the air outlet in the wall should not be greater than 1m, while the distance
from any other edge to the wall should not be smaller than 1m.

(2) When two or more units are installed in a room, the distance between two units should not be smaller than 2m.

(3) Good ventilating conditions should be provided indoors to ensure the convection of hot and cold air.

(4) The distance between the circulating water pool and the open-cooling unit depends on the unit’s power. For the unit below 200kW, the
distance should not exceed 5m and the water pool’s capacity should not be smaller than 4m3; water surface must be higher than the
water outlet of the engine; meanwhile, spraying cooling or cooling tank should be employed (see Attached Fig. 1).

6. Output Power

(1) When the ambient temperature is 40oC, the altitude is 1000m and the relative humidity is 60%, the unit may keep running continuously
at the rated power.
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(2) If the above ambient conditions in (1) are exceeded, the output power of the unit should be corrected. The output power of the diesel
engine is corrected as specified in (4), and that of the generator is corrected according to GB755-81 “Basic Technical Requirements of
Motor”.

(3) When the unit works at the altitude of not higher than 1,500m and the ambient temperature of not higher than 38oC, it is allowed to run
at 100% of the rated power.

(4) The diesel engine outputs the rated power at the ambient temperature of 38oC, and the fuel system needs not adjusting as long as the
unit does not run overload. When the altitude exceeds 2,250m, the power should be reduced by 4% for every 300m higher; when the
ambient temperature exceeds 38oC, the power should be reduced by 2% for every 11 ℃ higher; correspondingly, the fuel system
should be adjusted to reduce fuel delivery, and the power of the unit will also decrease.

7. Eight electric performance targets of voltage and frequency of the unit are as follows:

Voltage Frequency
Stable Instantaneous Recovery Stable Instantaneous Recovery
Fluctuation Fluctuation
Regulating Regulating Time Regulating Regulating Time
Rate Rate
Rate (%) Rate (%) (Sec.) Rate (%) Rate (%) (Sec.)
0~5
±2.5 20~15 6 1
Adjustable ±10 5 1

Note: (1) When the unit is under 0~25% of the rated load, the fluctuation rates of its voltage and frequency are allowed to be 0.5 bigger
than the figures listed in the table.

(2) In the calculation of stable voltage regulating rate, the voltage change from the cold to hot state; the hot state means the state
that the unit runs continuously under the rated mode.

Chapter III. Installation Guide

The following circumstances should be taken into account for the installation of the unit. Please refer to Attached Fig. 2, 3 and 4.

1. Aboveground installation

The most ideal position of the machine room should be aboveground, and far away from other buildings. This way, the influences caused by
the unit’s vibration and noise may be reduced, and also a good working environment may be provided for maintenance personnel.

If the unit is required to work in an open field and no cement or brick machine room can be built, a temporary shed may be built with iron sheet
and asbestos shingle to shelter the unit from wind, rain and sunshine; the ground must be even and solid, and be covered with rubber
cushions.

2. Underground installation

If the unit has to be installed in the basement, then the air change volume necessary for the unit’s working and heat spreading should be
ensured.

3. Machine room

In the machine room, there must be adequate space and passage for operators’ convenience in inspection and maintenance. The distance
between one end of the water tank of the unit and the wall should not be greater than 1m to avoid blocking air exhaust because blocked air
exhaust may heat the water tank and thus heat cooling water. If it is really difficult to make arrangement in the way as said in the above, an air
scoop may be mounted to exhaust air outdoors directly.

If two or more units are installed in a room, the distance between two units should not be smaller than 2m. When noise control is required, the
silent-type unit is available, or noise reduction measures may be taken in the machine room.

4. Gas exhaust system

When the unit is installed indoors, the waste gas discharged by the diesel engine should be exhausted to an appropriate outdoor place. The
most ideal place is the downwind side of the house. Never exhaust waste gas toward the door/window or the air intake of the machine room.

Gas exhaust pipe should be shorter and straighter, but should not include more than 3
elbows, which should be jointed in arc form. A flexible pipe should be attached to the joint
of the external exhaust pipe and the exhaust outlet of the unit. The external exhaust pipe
should be supported by other brackets separately, but cannot press the flexible pipe.

As the temperature of waste gas is high, and even up to 700oC in some diesel engines,
combustible articles must be kept away from waste gas. When the exhaust pipe needs to
pass through the wall, it is required that a bigger round pipe (whose inner diameter should
be about 25mm bigger than the outer diameter of the exhaust pipe) should be fitted in the
wall, and the big pipe should be filled with heat insulating materials. It not only supports
the exhaust pipe, but also ensures heat insulation.

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5. Air intake

The air intake should be positioned near the tail end of the generator part of the unit, and
be parallel and at the same elevation as the generator shaft. The area of the air intake
should be above 50% bigger than that of the water tank. Too small air intake may cause
pressure drop in the machine room and then power reduction of the diesel engine.

To ensure constant temperature in the machine room and avoid the influences of wind and
rain, louvers may be used. However, be cautious that the area of the air gap of the louver
should be 25% bigger than that of the above-said air intake.

6. Fuel Tank Position & Fuel Line

The fuel tank is required to store the fuel necessary for working for 8 hours and above. It
would be better to separate the fuel tank from the unit and to position the fuel tank higher
than the fuel pump of the unit. When installed underground, the fuel tank’s position should
not be 1m lower than the center of the fuel feed pump, and the inlet port of the sucker must be 50mm higher than the bottom of the fuel tank in
order to avoid sucking sediments to block the fuel line. The refilling port of the fuel tank should be provided with a filter screen to prevent
impurities from entering the oil tank. The bottom of the oil tank must be provided with a discharge valve for the convenience of cleaning.

The oil tank should be made of uncoated mild steel, but not galvanized iron sheet because zinc film can react with fuel to form a kind of
substance harmful to the fuel injection nozzle.

7. Electric

It would be better to use flexible three-phase four-core copper cables as power cables. Cable end should be crimp-connected via copper wire
lug and zinc cover. The section of power cable depends on the unit’s capacity, the ambient temperature, the laying mode of cable and the
distance from the load to the unit. See the details of the electric installation documents. Norman is ready to provide you with satisfactory
solutions.

The best solution is to place cables in an underground cable trench, and then cover the trench. The cable trench should be provided with a
drainage system to protect cable from being immersed in water and oil.

The depth of the cable trench depends on the size of cable, but must allows cable to be
introduced into the trench vertically; the curvature radius of cable should not be smaller than
10 times of the outer diameter of cable. In most cases, the cable trench is 0.5m wide and
0.5m deep; but when the voltage exceeds 600kVA, the depth of the cable trench needs
increasing to 1m.

If cable is laid along walls, it must be fixed to walls, and its lower end should pass through a
protective sleeve not 1.5m lower than the ground level.

In laying, cable cannot be too tight or loose, and adequate allowances should be left at both
ends. During cable laying, the temperature should not lower than 0oC.

8. Installation of earth wire

According to the Design Specifications of Internal Combustion Power Station, the diesel generator employs the three-phase four-wire neutral
point direct earthing mode; thus, the neutral point earthing of the generator is essential to the installation of the unit. If the neutral point were
not earthed, the neutral wire (also known as zero wire), like phase wire, would form a great capacity pressure difference with the ground;
additionally, people usually think that zero wire is not live, and probably touch it to cause
electric shock; it would be extremely dangerous. The earthing resistance of the earth wire
should not be greater than 4Ω.

9. Safety and fire prevention

If water vapor enters the motor, it will be fatally dangerous. Don’t install any water tap near
the air intake. Keep water bucket away from the unit.

In machine room design, fire safety should be taken into consideration, and the machine
room should be provided with fire-extinguishing facilities. The fire safety of the machine room
should be accepted by the fire department.

The control panel of the unit should be close to the entrance door. In case of any accident, it
will be very convenient to shut down the unit.

The above statements are for reference only can design a machine room for you, and also provide further detailed information.

Chapter IV. Operation Guide

1. Preparations before the start-up of the unit

(1) Check all parts of the diesel generator for normal working conditions, all
accessories and fasteners for reliable fixing, and the control mechanism for
flexible and reliable running. Any abnormal condition or impurity that obstructs
the running of the unit should be eliminated and settled immediately.

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(2) The electric wiring of the unit has been completed prior to delivery. In consideration of bump and shake in long-distance transport, the
user needs to check the nut(s) of each joint of the line for firm fixing and good contact and check each circuit for correct wiring by
referring to the electric schematic diagram and the electric wiring diagram prior to the start-up of the unit.

(3) If the unit is not used for a long term, check electric circuits for dampness and also check insulations. Use a 500V mega meter to
measure the insulation resistance of main loop and control loop; the insulation
resistance at cold state should not be smaller than 2M Ω . (Be cautious that
silicon rectifying cell should be short-circuited in insulation measurement; the
electric wires affected with damp should be dried with the resistance current
method until they satisfy relevant requirements. In the control box, trouble spots
in insulation should be find out for settlement).

(4) Check the wiring of the electric start-up system for normality and the storage battery for
sufficiency. The electrolyte’s density should not be lower than 1.27g/CM (at 15oC); add
distilled water when the liquid level is too low.

(5) Check the cooling system for normality. The open cooling system, should be
connected with water supply, and its water level should be higher than the
generator; for the closed cooling system, check whether cooling water is filled up,
and add cooling water if water is not enough.

(6) Check the fuel system for normality and the fuel amount in the tank for
adequateness. Open the switch of the fuel system, and use a hand pump for
refilling fuel when necessary. In refilling fuel, loosen the bleeding screw on the
injection pump to release the air in the fuel system until there is no air bubble in
the overflowing fuel, and then fasten the bleeding screw to pump fuel
continuously until there is fuel in the return fuel pipe; fasten the hand pump.

(7) Check the level of engine oil to see whether it is within the scale range of the oil
scale. If engine oil is not enough, use the same grade engine oil, and refill it to
the scale range.

(8) Check the air intake system for normality and the air filter for good working conditions.

(9) Check the wiring of output circuits of the generator for normality and the meters and switches on the control panel for normality and
reliability.

(10) The output switch is at the off position.

2. Start-up of the unit

(1) Adjust the rotating speed to the position of 850rpm. For the low lower generator unit with the rated rotating speed of 1,500rpm, it should
be adjusted to the position of 1,500rpm.

(2) When use the key to turn on the unit with protective device, check the low oil pressure alarm lamp of engine oil. If the lamp is on, it
means it is at good working conditions. Start the unit 4~5 seconds later.

(3) If the engine with air preheating device needs preheating, the preheating heater plug should be powered on for 10 seconds, and then
the diesel engine may be started. If the diesel engine is not started in 10 seconds,
release the start button, and start it two minutes later. If startup operation fails for
three times continuously, stop startup operation, find out causes and remove
troubles prior to the fourth-time startup.

(4) After the unit is started and runs, release the start button immediately. The finger of
the charging ammeter points to the positive position, which means the charging set
is working normally. Here, the low oil pressure alarm lamp of the unit with protective
device should be off. If the emergency lamp is not off, it indicates that the engine oil
pressure is too low; stop the unit immediately to check the unit.

(5) After the unit is started, the rotating speed should be controlled within 850rpm
usually for less than 30 minutes. The unit cannot run at such speed for a long time.

(6) After the unit is started, pay close attention to the readings of all meters, and check the running status of each part of the unit at once.
Remove any abnormality immediately. When the unit runs normally, record the
startup and running time.

3. Management during the unit’s working

(1) After the unit is started and runs normally, the rotating speed should be gradually
increased from 850rpm to 1,500rpm. For the lower power unit with the rated rotating
speed of 1,500rpm, the diesel engine needs warming up firstly.

(2) Generally, the unit can be accelerated to the rated rotating speed (i.e. frequency
50HZ) when the discharge temperature in the warming up of the diesel engine
reaches 45oC (except under emergencies).

(3) If the generator cannot generate voltage automatically, magnetize the generator, and then adjust voltage setting and resistance. Adjust
the no-load voltage to 400V.

(4) Close the air output switch, and switch on the load to supply power to the load.

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(5) If the unit is in parallel operation, usually adopt the lighting method or use a synchronous meter for manual parallel operation. Operators
are required to close the switch of the unit (to be put in parallel operation) skillfully and rapidly to avoid asynchronous impact.

(6) If parallel operation fails for several times, remove the load and cancel parallel operation, and adjust the stable regulating rate of single
unit.

(7) After the unit is in normal power supply operation, check the working condition of
each part of the unit from time to time, and observe various meters and alarm lamps
frequently to see whether they are at normal working conditions. Record the
readings of the meters every hour.

(8) Check the volumes of diesel and engine oil regularly. Refill fuel immediately when
the fuel level is lower than the 1/3 position of the fuel tank.

(9) Load increase and decrease should take place evenly; except under emergencies,
sudden load increase or removal is not allowed. When the discharge temperature of
the diesel engine reaches 55oC, and the engine oil temperature reaches 45oC, it is
allowed to increase to the full load.

(10) When the diesel generator unit is used for a long time, it can run under 90% of rated load. The unit can run under rated load for 12 hours
continuously at most.

(11) During the normal operation of the silent-type generator, open the door regularly to see whether the unit is running normally, and record
the readings of the meters. Remove any abnormality in time.

(12) The new or heavy-repaired diesel engine need go through 60h trial running prior to formal use, and then can be put in full-load use.
Throughout the trial running stage, the load should be 50%~80% of the rated power of the unit. Never allow the unit to run idle for a long
time. During the use of the unit, check and replace “three filters” (air filter, diesel filter and engine filter) regularly and check the unit for
“three leakages” (air leakage, oil leakage and water leakage) from time to time. In case of “three leakages”, conduct repair in time.

4. Shutdown of the unit

(1) Gradually remove the load of the generator, and cut off the air output switch.

(2) Gradually reduce the rotating speed, and shut down the unit after it runs for 3~5
minutes. Try to avoid stop the unit under full load suddenly in order to prevent overheat
accident. Set the electric key to the off position and take the key out.

(3) Bring the fuel system to the state prior to startup, and cut off the delivery vale of the
fuel tank.

(4) For the open cooling system, cut off the water supply and the water valve. When the
ambient temperature is lower than 0oC in winter, to protect the unit’s parts from
frostbite, the water in the cooling system should be discharged after shutdown (unless
the antifreeze liquid is added).

(5) The diesel generator unit not in use for a long time should be provided with an oil seal. Every week, the unit without oil seal must be
started and run for 5~10 minutes to prevent the unit’s parts from getting rust,
especially internal parts.

(6) Emergency stop of the diesel generator unit. Under emergent or special
circumstances, the unit must be stopped to avoid serious accidents. Cut off the air
output switch quickly, remove the unit’s load, and push the emergency stop button or
move the emergency stop throttle control handle to the position of stopping feeding
fuel; then, the unit stops running immediately.

(7) After the unit stops running, check and clean the outside of the unit, and wipe off oil
stain and dust on the unit to keep the unit ready for use at any time. Record the
shutdown time.

Chapter V. Maintenance Guide

To ensure the normal running of the diesel generator unit and prolong the service life of the
unit, you must check, adjust and clean the unit periodically to create good conditions necessary
for the unit to run and prevent early wearing and failure. The operator must follow the
instructions in the below:

1. Routine maintenance

2. 1st-level technical maintenance

3. 2nd-level technical maintenance

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4. 3rd-level technical maintenance

1. Routine maintenance after every shift

(1) Check coupling bolts of rotating members for fastening, and fasten any loose bolt
in time.

(2) Check the engine oil level in the oil sump (oil scale).

(3) Check the volume of fuel in the fuel tank.

(4) Check the water level of the water tank.

(5) Check the joints of fuel and water pipelines.

(6) Check the gaskets of air intake pipe, exhaust pipe and cylinder for tightness.

(7) Clean oil stains and dust on the surface.

2. 1st-level technical maintenance (50 hours)

In addition to the contents of routine maintenance, the following items are added:

(1) Check the filter element of the air filter.

(2) Replace the fuel filter and the filter screen in front of the hand pump.

(3) Check the tensioning of the rubber strip.

(4) Replace cooling water and engine oil.

(5) Apply butter to the bearing of the water pump.

3. 2nd-level technical maintenance (200 hours)

In addition to the items of the 1st-level technical maintenance, the following contents are added:

(1) Replace the filter elements of the air filter, the engine oil filter and the fuel filter.

(2) Replace the engine oil in the oil sump.

(3) Check and adjust the valve clearance.

4. 3rd-level technical maintenance (running for 500 hours in total)

In addition to the contents of the 2nd-level technical maintenance, the following items should be added:

(1) Check and adjust the oil injection advance angle.

(2) Check the spraying of the nozzle.

a. Sprayed fuel should be fogging;

b. The nozzle orifice should not have oil drip.

c. If injection pressure is not enough, use a screwdriver to rotate the adjusting screw to adjust fuel injection pressure.

(3) Clean the fuel tank.

(4) Clean the oil sump.

(5) Replace the engine oil in the injection pump.

(6) Check the fastening moments of connecting rod bolt, main bearing bolt and cylinder cover’s bolt。

5. Routine maintenance of the generator

(1) Protect the generator from damp, and cover it with a cloth to when it is not is use.

(2) Metal chips, water drops, dust, water vapor and other hazardous gas should be prevented from entering the generator.

(3) When the generator is running, good ventilation should be ensured. There should not be any cover on the external surface of the
generator so as to facilitate ventilation and heat emission.

(4) Check the temperature of the bearing every four hours in each shift, and observe the sound of the bearing for any abnormality.

6. Routine maintenance of the storage battery

(1) Ensure good ventilation for the storage battery, and protect it from water, oil, dust or heavy impact.

(2) Clean the terminals and surface of the storage battery every day. The electrolyte level is required to exceed the pole plate by 10~15mm;
the density of the electrolyte should be within 1.28~1.30 at 25oC; otherwise, distilled water should be added.

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7. Maintenance of the starting motor

(1) The starting motor is working under high current for a short time, and connections are required to be firm. Check terminal posts for any
damage or color change.

(2) The storage battery and other power supply should be free of oil stain, etc.

8. Maintenance of the charging generator

For the sake of safety, never check the charging set when the unit is running, but check the external wiring of the motor and the voltage
regulator for fastening and the driving belt for tightness. Besides, the disassembly check and maintenance of the charging set should be
conducted together with the 3rd-level protection of the unit.

9. Maintenance of the control box

(1) Open the control box regularly (twice per shift) to see whether any terminal post gets loose, overheated or faded.

(2) Clean the control box regularly (once per shift) to keep meters clean, smooth, readable, complete and bright.

10. Maintenance of instruments and meters

(1) Often use a handle air blower to below off dust on current transformer, voltage transformer, etc. to keep them clean.

(2) Meters should be sent to the testing department for calibration every year (annual inspection).

Chapter VI. Repair Guide

Diesel Generator is an advanced unit coming with various automatic control functions. To keep it under good technical conditions and prolong
its service life, besides proper installation, use, operation and maintenance of the unit, proper repair should be also conducted for the unit’s
problems and troubles to resume its good technical status during use. The unit’s repair involves such stages as disassembly, cleaning, repair and
reassembly.

1. Disassembly of the unit

(1) Preparation before disassembly

1 Site requirements: the disassembly and repair site should be big enough,
even, clean and bright, and be located indoors so as to facilitate the smooth
proceeding of repair work.

2 Tool preparation: necessary tools should be prepared according to the scope

and specific requirements of repair work.

Common tools: various open end wrenches, box wrenches, socket wrenches,
moment wrenches, screwdrivers, nippers, etc.

Special tools: tools for dismounting valves and rolling bearings, etc.

Measuring tools: micrometers, clock gauges, vernier calipers, clearance gauges, etc.

Heavy tools and other apparatuses: pulleys, oil tanks, oil pans, etc.

3 Technical document preparation: instruction manuals, disassembly & assembly technical requirements, repair standards of
necessary parts and accessories, etc.

(2) Main rules for disassembly

1 According to the requirements of repair items and disassembly process, various parts should be dismounted correctly.

2 Prepare and select disassembly tools and equipment. For some complicated parts, disassembly procedures should be carefully
analyzed to prevent brutal disassembly and part damage. Use diesel for immerse or heating, and start disassembly after
appropriate knocking.

3 Disassembled parts should be placed in order. Important parts should be affixed with proper marks and labels. Disassembled oil
ducts and water ducts should be wrapped with cloth to prevent mud, sand and dirty substance from getting in.

4 For any part with certain assembly direction and position, pay attention to original marks. If original marks are not clear, new
marks may be made. Don’t punch marks on any contact surface.

5 Disassembled bolts, nuts, gaskets and spacers should be mounted to original positions or placed according to their categories.
Don’t litter them everywhere.

6 Determine part and accessory disassembly scope according to repair needs; those that do not need disassembling should not be
disassembled; otherwise, the working lives of parts and accessories may be affected.

7 Repair and replace any damaged or worn connecting or fastening piece founded in disassembly.
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(3) General method for part disassembly

1 A suitable spanner should be selected to dismount screwed connections. Wrench screwed connections with appropriate force to
avoid damaging edges and corners with too big force. Use a special tool to remove studs.

2 A special detacher puller can be used for dismounting too-tight-connected parts.

3 For key joints, the same method can be adopted as the too-tight-connected parts.

(4) Crane operation rules

1 Strictly prohibit overweight hoisting.

2 At the contact place between wire ropes and parts, a wood block should be placed to prevent crushing parts.

3 Check ropes and fittings to see whether they are reliable and under even stress prior to hoisting. When weights is 5~10cm above
the ground, vibrate or shake the rope to see whether it is reliable.

4 Prevent too fast rise or fall in hoisting. Never stand below hoisted weights. When a weight is hoisted to the required position,
place it slowly and steadily.

2. Cleaning and check of parts

Part cleaning is also one of the repair methods. Disassembled parts must be cleaned. Typical cleaning methods include oil wash and
mechanical cleaning.

(1) Greasy stains are usually removed with the oil wash method. Precision parts like plunger, plunger sleeve, injection nozzle and rolling
bearing should be cleaned with gasoline; after cleaning, they should be dried with compressed air.

(2) Removal of carbon deposit: carbon deposits are often removed with the mechanical cleaning method; according to the material nature
of parts and accessories, suitable tools like chisel, scraper and brush can be used. Be cautious not to damage the surface of parts and
accessories.

(3) Incrustation removal: the incrustation inside the cooling water tank can be chiseled off manually or removed by adding the cleaning
liquid (150g caustic soda in 1kg water) in the closed cooling system, keeping it in the system fro 8~12 hours and running the unit to
75oC.

(4) Test and check cleaned parts and accessories according to repair criterions, and then decide to repair or replace them.

3. Assembly of the unit

The unit should be assembled in the reverse order of disassembly. The general principle is from internal to external, from main parts to
auxiliary ones, and simultaneous assembly and adjustment. Main assembly procedures include:

(1) Parts should be cleaned; particularly, the lubrication system needs a thorough cleaning.

(2) Sliding contact surface should be free of burs or scratch. Clean lubricant should be applied prior to assembly.

(3) Select and use suitable tools. Bolt screwing procedures must comply with relevant technical requirements.

(4) For the rolling bearings with inner diameter greater than 35mm, the hot assembly method should be adopted. Place the bearing in the
90~100oC for heating, and put it in the journal. Those with inner diameter smaller than 35mm cannot be heated, but can be assembled
through hammering; but hammering position must be at the inner ring.

(5) The parts and accessories with certain directions and marks should be assembled according to such directions and marks; never make
mistake in assembly.

(6) Asbestos, paper and cork gaskets should be replaced to keep original thickness; if remaining intact, metal gaskets may be used again
but need to go through annealing treatment.

(7) Any worn or deformed bolt should be replaced. Double-ended bolt should be fastened to the end. For the screws with certain installation
subsequence and tightening force, nuts should be fastened according to such subsequence and moment.

(8) All required locking parts including cotter pin, lock washer, spring shim and relief spring should be installed according to the technical
requirements.

(9) The joints of oil and water lines and intake and outlet pipes should be tight; washers, gaskets, gum rings and gum covers should be
used according to the technical requirements and be tight.

(10) In mounting the parts, rotate the parts to see whether it is jammed. After assembly is completed, run the crankshaft to conduct an overall
check, and eliminate any trouble in time.

4. Repair of the generator

(1) Take the core out of the generator for repair once every year, and check and test the insulations of each circuit.

(2) In dismounting the generator, there are two opening boltholes beside the flange on either of front and rear end caps. To dismount end
caps, remove the bolts of the front end cap firstly, and then screw the removed bolts into the boltholes on the rear end cap to eject the
end cap gradually. This way, end caps are under even stress, and are not easy to deform or crack.

(3) Generally, lubricating grease should be replaced when the unit runs for 2,000 hours. Clean up the old grease in the bearing chamber

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 GENERATOR USER`S MANUAL

prior to replacing lubricating grease. Use kerosene to wash the chamber, and different grade bearing greases cannot be mixed for use.
The volume of bearing grease to be added should be 1/3~1/2 of the capacity of the bearing chamber. Too much bearing grease may
cause overheat of the bearing.

(4) When dismounting bearing cap and bearing, use a puller to pull off the bearing, and cover the dismounted parts with clean paper
properly to protect them from dust.

(5) The rust or stain on the surface of the collector ring may be wiped off with a roving cloth dripped with little alcohol or other solution, or
gently grinded with #00 sand paper. In case of any serious sear, it should be processed on the lathe. In processing, it should be
concentric with two bearing guards in order to prevent the collector ring from jumping in rotation.

(6) The electric brush’s pressure is 200~250g/cm2. If the motor is installed at a place with violent vibration, the brush’s pressure should be
300~350g/cm2. The fixing of the brush and the brush holder frame should be appropriately tight. Serious worn brush should be replaced.
Use a fine sand paper to grind the face of the new brush in contact with the collector ring into an arc (this paragraph is not applicable to
brush-less motor).

(7) Open the motor, check the inside and use dry compressed air to blow and clean dust buildup on conductive surface to prevent electric
discharge on surface. The surface of each circuit and the inside of the fan should also be cleaned thoroughly to ensure effected
ventilation and heat emission.

(8) When dismounting the connector lugs of the generator and the excitation device, pay attention to the labels. If any label goes missing or
becomes unclear, check and rearrange labels. In assembly, wires should be connected to their original positions, and never make
mistake in wiring.

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